U.S. patent number 3,612,387 [Application Number 05/001,234] was granted by the patent office on 1971-10-12 for brazing method and apparatus.
This patent grant is currently assigned to Aeronca, Inc.. Invention is credited to Robert R. Rathbun.
United States Patent |
3,612,387 |
Rathbun |
October 12, 1971 |
BRAZING METHOD AND APPARATUS
Abstract
A method and apparatus are disclosed for brazing articles such
as honeycomb sandwich structures. The apparatus includes a cold
wall boxlike housing separable into upper and lower sections. Each
section carries a ceramic die member provided with passageways
terminating in small ports for conducting a cooling fluid adjacent
to the work. The workpiece is heated by electrical resistance
heater strips passing above and below the workpiece. Means are
provided for evacuating the housing and backfilling it with argon.
When the workpiece is brought to brazing temperature, two
expandable bags are inflated. One bag raises the lower die section
to form a general fit with the upper one. The second bag is in
direct contact with the upper face of the workpiece and exerts a
uniform pressure normal to its surface. After brazing, the bags are
deflated and chilled argon is introduced through the die passages
to cool the work. Other features include localized temperature
control by electron emission or cooling tubes and vapor removal by
means of a cold trap.
Inventors: |
Rathbun; Robert R. (Middletown,
OH) |
Assignee: |
Aeronca, Inc. (Middletown,
OH)
|
Family
ID: |
21695034 |
Appl.
No.: |
05/001,234 |
Filed: |
January 7, 1970 |
Current U.S.
Class: |
228/6.1;
228/44.3; 269/22 |
Current CPC
Class: |
B23K
1/0014 (20130101); B23K 2101/02 (20180801) |
Current International
Class: |
B23K
1/00 (20060101); B23k 005/00 (); B23k 001/00 () |
Field of
Search: |
;228/4,6,44,47,49
;269/22 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Campbell; John F.
Assistant Examiner: Lazarus; Richard Bernard
Claims
Having described my invention, I claim:
1. Apparatus for brazing a composite sandwich member, said
apparatus comprising:
an upper boxlike housing section,
a lower boxlike housing section, each of said sections having a
peripheral flange,
means for raising and lowering said upper housing relative to said
lower housing,
said flanges on the upper and lower housings being disposed in
engagement with one another when said upper housing member is
lowered into contact with said lower housing member,
clamping means for holding said flanges in sealing airtight
relationship,
a first die member mounted within and carried by said upper housing
section,
a second die member mounted within said lower housing section, said
first and second die members having opposed working faces,
each of said die members further including a plurality of internal
passageways and interconnecting ports opening on said work
face,
one of said die sections being movable mounted within its
associated housing section for movement toward the opposite die
member,
a first expandable bag member interposed between said die member
and a wall of said associated housing section for effecting
movement of said die member toward the opposite die member,
resistance heating elements interposed between each of said die
members and said composite sandwich member,
means for evacuating the interior of said housing sections,
means for introducing an inert gas into said housing sections,
means for introducing a coolant fluid into said passageways in each
of said die sections,
and means for selectively evacuating and pressurizing said
expandable bag member.
2. The apparatus of claim 1 further comprising a second expandable
bag member interposed between one of said die sections and the
sandwich being brazed, said second bag member assuming a
configuration conforming to the adjacent die face, and means for
selectively evacuating and pressurizing said bag member.
3. The apparatus of claim 1 further comprising a cold trap having
an airtight chamber in communication with the interior of said
housing sections and a well adapted to contain a cooling
medium.
4. The apparatus of claim 1 in which said upper die member is
rigidly mounted within said upper die section and said lower die
member is movable mounted relative to said lower die section,
guide means mounted within the lower section for restricting
movements of said lower die member to movements in a vertical
direction,
said first expandable bag member being interposed between said
lower die member and the bottom wall of said lower housing
section.
5. Apparatus of claim 1 further comprising a second expandable bag
interposed between the upper die and the sandwich member being
brazed, said second expandable bag having the configuration of the
working face of the upper die member.
6. Apparatus of claim 4 further comprising a second expandable bag
interposed between the upper die and the sandwich member being
brazed, said second expandable bag having the configuration of the
working face of the upper die member.
7. The apparatus of claim 1 in which each of said passageways
extends longitudinally of said die member substantially the length
thereof, a manifold interconnected to each of said passageways,
each of said ports extending transversely from said passageways to
the working face of the die.
8. Apparatus of claim 1 further comprising means for effecting
localized cooling of the edges of said sandwich member being
brazed.
9. Apparatus of claim 7 in which said means comprise a probe
disposed adjacent to said resistance heating elements at the side
of the member being brazed, a source of high DC potential, means
connecting said source of potential so that said probe is negative
relative to said resistance heating means and electrons are emitted
from said resistance beating means to said probe to lower the
temperature of the resistance heating elements in the area of said
emission.
10. The apparatus of claim 8 in which said means comprise tubes
adapted to carry cooling water disposed adjacent to said resistance
heating elements at the side of said sandwich member being brazed.
Description
BACKGROUND OF THE INVENTION
This invention relates to a new and improved method and apparatus
of brazing composite honeycomb core panels.
The present invention is particularly useful in connection with the
brazing of stainless steel honeycomb panels of the type utilized in
the construction of supersonic speed aircraft, space vehicles and
the like. Panels of this type are subjected to high temperature
during use and, accordingly, are formed from stainless steel
surface sheets brazed to the opposite sides of a center honeycomb
core formed of stainless steel. These panels are manufactured to
meet high structural requirements with the result that the brazed
joints must be substantially flawless.
In the past, many different techniques have been proposed for
fabricating honeycomb panels of this type. Those techniques which
have been practical enough to produce the high quality panels
required have been very expensive and time consuming.
Accordingly, it is the principal object of the present invention to
provide a new method and apparatus for brazing honeycomb sandwich
structures at a substantial reduction in cost and in substantially
less time than was possible with previous methods. The utilization
of the present method and apparatus also facilitates the production
of superior honeycomb structural members having improved brazed
joints and surface characteristics, e.g. lack of wrinkling and the
like.
More particularly, the brazing apparatus of the present invention
includes a two-piece, boxlike cold wall enclosure. The enclosure
consists of upper and lower sections with mating peripheral
flanges. During a brazing operation the sections are clamped
together and an airtight joint is formed by an O-ring carried by
one of the flanges and compressed into sealed relationship with the
opposite flange. Each housing section carries a cast stable die
member preferably formed of a suitable ceramic, such as Glasrock or
the like. Means are provided for raising the upper housing member
and its die an appreciable distance above the lower housing member
so that easy access is provided to both die members and the
interior of the housing. This greatly facilitates set up of the
tool and loading and unloading of the honeycomb panel being
brazed.
Each die member has a working face and a plurality of internal
coolant passages which communicate with the face through a
plurality of small ports. The coolant passages of each die are
interconnected through a manifold to a cooling gas line. In the
preferred embodiment the lower die is shiftable within the housing
toward and away from the upper die. These movements are effected be
means of an inflatable bag mounted beneath the lower die between
that die and the bottom wall of the lower housing.
The workpiece is heated by means of electrical resistance heater
strips which extend transversely between the workpiece and the
upper and lower die members respectively. A second pressure bag is
disposed between the upper heater strips and the upper surface of
the sandwich structure. This upper bag conforms itself to the
configuration of the upper die and when inflated is effective to
apply a substantially uniform pressure normal to the surface of the
sandwich structure no matter whether that surface is planar or
curved.
The apparatus also includes a connection to a vacuum pump and a
connection to a source of inert gas, such as argon. Although it is
preferable to carry out the brazing operation in an inert
atmosphere, such as argon, the present apparatus can also be
utilized to carry out a brazing operation under a hard vacuum. In
accordance with one aspect of the present invention, the amount of
moisture within the enclosure is minimized by means of a cold strap
which communicates with the housing and includes an airtight
chamber at least one wall of which is common with a well containing
a cold material, such as liquid nitrogen. The gas within the tank
is circulated through the chamber where water vapor is condensed
and freezes on the cold wall. This vapor is thus held away from the
sandwich material being brazed.
One of the principal advantages of this apparatus is that it
facilitates the utilization of a very rapid brazing cycle. For
example, in a typical brazing operation the brazing apparatus can
be loaded in approximately 15 minutes. The enclosure can be purged
and back-filled with an inert gas and the part brought up to
brazing temperature in 1 hour. Thereafter, the brazed part can be
directly cooled in 1 hour by introducing a cooling gas, such as
chilled argon, through the apertures in the die. This 2-hour cycle
is approximately one-seventh the length of time required in a
conventional brazing operation. Moreover, the savings in labor and
expendable materials can run as high as 74 percent for a given
part.
In accordance with the present brazing method, the sandwich
structure to be brazed is placed over the lower die member. This
die member has previously been covered with an insulating blanket,
resistance heater strips and other conventional elements, such as
slip sheets and the like. A slip sheet and inflatable bag are
placed above the sandwich member and are then covered with
resistance heating strips, an insulating sheet and blanket. The
upper housing member is then lowered and clamped to the lower
housing member to form an airtight closure around the dies. Both
the upper bag above the sandwich and the lower bag below the lower
die are evacuated. The enclosure itself is then evacuated and
back-filled with argon. This may be repeated one or more times.
In the preferred method, after the final back-filling of argon to a
pressure of the order of 5" of mercury, the temperature and the
workpiece are raised by the resistance heaters to brazing
temperature. The lower bag is then inflated to raise the lower die.
This causes the die members and workpiece to seat relative to one
another. Thereafter, the upper bag is inflated to apply a uniform
brazing force normal to the surface of the sandwich structure.
After the brazing has been completed, the electrical resistance
heaters are deenergized and the pressure bags are again evacuated.
A cooling gas, such as chilled argon, is introduced through the
passageways in the dies. The cooling gas issuing from the bottom
die is effective to lift the core from the bottom die st that the
core in effect is suspended and immersed in a stream of cooling
gas. After the core temperature has been reduced the desired
amount, the top housing section and its attached die member are
raised and the brazed structure is withdrawn.
In addition to the economics provided, this method is advantageous
in that it results in the production of a superior brazed panel
member. In the first place, the rapid elevation of the sandwich
member to brazing temperature and rapid cooling thereafter
minimizes any tendency of the brazing alloy to migrate or separate.
Secondly, the sandwich structure is not subjected to any
appreciable pressure during the time when it is being brought up to
brazing temperature. Thus, the skin is kept smooth and free from
wrinkles. Moreover, the brazed joint is uniform since the parts
have been subjected to a uniform pressure across their entire
surface.
Moreover, in accordance with another aspect of the present
invention, the brazed joint is also made uniform because the
temperature across the honeycomb structure is kept substantially
uniform. In accordance with the present invention, this uniform
temperature is maintained by effecting a local cooling adjacent to
one or both edges of the honeycomb structure which would otherwise
develop hot spots. This local cooling action is obtained either by
causing an emission of electrons from the electrical heating means
in this area or by causing radiation of heat from the electrical
heating means in this area to a sink in the form of a tube through
which cooling water is fed when cooling is required.
In accordance with a further aspect of the present method, a
sandwich structure can be creep formed simultaneously with the
brazing operation. More particularly, a sandwich structure which is
to be given a curved configuration is not completely preformed
prior to the brazing operation, but is either inserted between the
dies in a planar condition or in only a partially curved condition.
The pressure exerted upon the structure when it is at the brazing
temperature by the upper pressure bag not only causes the formation
of a braze joint, but also bends the sandwich into its final shape
conforming to that of the die faces.
These and other objects and advantages of the present invention
will be more readily apparent from a consideration of the following
detailed description of the drawings illustrating the manner in
which the present process is carried out and a preferred form of
apparatus for practicing the process.
DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a perspective view, partially broken away, of a typical
honeycomb core member fabricated in accordance with the principles
of the present invention.
FIG. 2 is a perspective view of a preferred form of brazing
apparatus for carrying out the present brazing method.
FIG. 3 is a transverse cross-sectional view of the brazing
apparatus with the top in a lowered position. The view is taken
generally along line 3--3 OF FIG. 2 (except that the top is lowered
and the lower bag is inflated).
FIG. 4 is a cross-sectional view similar to FIG. 3 with the lower
bag deflated.
FIG. 5 is a semidiagrammatic perspective view of one form of core
heating and temperature control unit.
FIG. 6 is an enlarged, generally diagrammatic, partially exploded,
cross-sectional view taken through the upper and lower die members,
the sandwich panel being fabricated, and the heater strips.
FIG. 7 is a cross-sectional view taken along line 7--7 of FIG. 2
showing a clamp for securing the upper and lower housing members
together.
FIG. 8 is a diagrammatic view of a vapor trap utilized in
connection with the present brazing apparatus.
FIG. 9 is an end view of one form of brazing apparatus constructed
in accordance with the present invention.
FIG. 10 is a diagrammatic view illustrating a modified form of a
temperature control.
APPARATUS
The present apparatus is particularly useful in the fabrication of
honeycomb sandwich structures. One such honeycomb sandwich panel 10
is shown in FIG. 1. This panel comprises two outer skin sheets, or
faces, 11 and 12 and an inner honeycomb core 13. The skins, or
faces, 11 and 12 in a typical structure are formed from sheets such
as stainless steel or Inconel. The honeycomb core is likewise
formed from a thin metal foil of the order of, for example, 0.002
inch thick.
The core is preformed using any suitable technique, such as spot
welding together adjacent corrugated strips along their abutting
nodal portions. The honeycomb core and panels are joined together
by a suitable braze alloy comprising, for example, 23 percent
manganese, 4 percent copper, 2 percent silicon and 71 percent
nickel. The braze compound can be applied to the exposed edges of
the honeycomb core in any suitable manner, such as by dipping the
core in a braze powder, by spraying the core with a powder, or by
utilizing the braze alloy in the form of a thin sheet interposed
between the core and skin sheets. It is to be understood that whole
the present method can be utilized to great advantage in the
brazing of compound curved panels, such as the panel shown in FIG.
1, it can also be used in the fabrication of simply curved panels
or planar panels.
The overall construction of the brazing apparatus 14 is best shown
in FIGS. 2, 3 and 9. As there shown, the brazing apparatus 14
comprises a cold wall, boxlike, airtight exterior housing
consisting of upper section 15 and lower section 16. Lower housing
member 16 is stationary and is mounted upon a suitable base 17. The
upper housing is adapted to be raised and lowered relative to the
lower housing member 16 by any suitable form of elevating
mechanism, such as the counterweight, rope and pulley arrangement
18 shown diagrammatically in FIG. 9.
When upper housing 15 is in its elevated or storage position as
indicated in FIG. 9, it is spaced an appreciable distance from
lower housing 16, allowing ready access to the elements disposed
within both the upper and lower housing sections. In its operative
position, however, the upper housing is lowered into sealed
engagement with lower housing 16. This sealed engagement is
provided by outwardly extending peripheral flanges 20 and 21 formed
upon the upper and lower housing members 15 and 16
respectively.
As is best shown in FIG. 7, the housings are brought into precise
alignment by the interengagement of upstanding locating pins 22
carried by lower flange 21 and aligned openings 23 formed in upper
flange 20. The lower flange also carries an O-ring 24 which extends
completely around the flange in a peripheral channel 25. When the
upper flange 20 is clamped against the channel 25 of lower flange
21 as indicated by the dotted lines in FIG. 7, O-ring 24 is
compressed to provide a completely airtight seal around the entire
periphery of the mating upper and lower flanges 20 and 21.
The clamping force for holding the upper and lower housings
together is provided by a series of clamp mechanisms 26 as shown in
FIGS. 2 and 7. Each clamp mechanism comprises a generally C-shaped
clamp arm 27 pivotally mounted on a pivot pin 28 beneath lower
flange 21. The upper end of the C-clamp carries a clamp screw 30
having a handle 31 and a clamp foot 29 adapted to press against the
upper flange 20 to force that flange into tight engagement with the
lower flange 21.
The upper and lower housing members 15 and 16 each respectively
carry ceramic die members 32 and 33. These die members are
preferably formed of a suitable dimensionally stable ceramic
material, such as Glasrock. In accordance with the present
invention, the die members are movable relative to one another
within the confines of the outer housing members 15 and 16.
More particularly, in the specific embodiment shown, upper die
member 32 is rigidly mounted within upper housing member 15. As
shown in FIG. 3, upper die member 32 includes upper, outwardly
extending side flanges 34 which are engaged by Z-shaped angle
members 35. These angle members are bolted to the upper portion of
housing member 15 as by means of bolts 36 so that the upper surface
37 of the die member 32 is rigidly clamped in place against the top
wall 38 of housing member 15.
Upper die member 32 includes a lower wording face 40 having the
contour of the upper surface of the sandwich section 10 being
fabricated. The upper die section is further provided with a
plurality of longitudinally extending coolant fluid passageways 41
adapted to be connected to an upper manifold and supply tube (not
shown), but generally like the lower manifold 42 and tube 67 shown
in FIG. 2. Bores 41 extend from one end of the upper die member to
substantially the opposite end of the die member. Each of these
passageways is connected to a plurality of small ports 43 which
extend from the core to the working face 40 of the die. In the
embodiment shown, this face is smooth. However, in some embodiments
the face 40 can be provided with a network of longitudinal and
transverse grooves. In this case, the ports 43 communicate with the
grooves (not shown).
The lower die member 33 is mounted for limited vertical movement
within lower housing member 16. More particularly, die member 33
includes a horizontal bottom wall 47 which is disposed in
engagement with an inflatable bag 48 disposed between bottom
surface 47 of the die member and bottom wall 50 of the lower
housing member 16. Lower die member 33 also includes two opposed
vertical sidewalls 51 and 52. These walls are constrained against
lateral movement by means of stationary guide members 53 and 54.
Each of the guide members as shown is in the form of an angle
member having a bottom arm 55 welded or otherwise secured to the
bottom wall 50 of the housing member and upwardly extending arm 56
in engagement with one of the vertical walls 51 and 52 of the die
member. Similar guide members (not shown) are provided for
constraining endwise movement of the lower die member.
Lower member 33 includes an arcuate working face 57 conforming to
the configuration of the lower surface of braze composite 10, Die
member 33 also is provided with a plurality of longitudinally
extending coolant passages 58. These passages extend from one end
wall 60 of the lower die adjacent to the opposite end wall 61 of
the die. A connection is made to the coolant passages from a
manifold 42. This manifold is joined to a tube 67 which extends
through a sidewall 70 of lower housing section 16.
Passages 58 interconnect with a plurality of small bores 71. These
bores extend through to the working face 57 of the lower die member
which, in the embodiment shown, is smooth but which alternatively
may be provided with a plurality of longitudinal and transverse
grooves for distributing the coolant over the face of the working
die.
As indicated above, lower die member 33 is adapted for vertical
movement relative to the bottom wall 50 of the housing. This
movement is effected by means of an inflatable bag member, or
bladder, 48. In one preferred embodiment, bladder 48 is formed of
neoprene-coated dacron fabric. Alternatively, this bladder can be
fabricated from a thin flexible material, such as 321 stainless
steel of a thickness of approximately 0.015 inch. Bag 48 is
connected to a line 72 which extends from outside of the lower
housing through a wall of the housing as shown in FIG. 2.
In addition to these elements, the present tool includes a
connection of an argon back-fill line 73 which communicates with
the interior of the housing through sidewalls 74 (FIG. 2). A vacuum
line 75 is connected to the housing through sidewall 70. It is to
be understood that these and all other connections through the
walls of housing sections 15 and 16 are airtight.
Another major component of the brazing apparatus is the electrical
heating and temperature control system 76. Essentially, the
electrical heating system comprises a plurality of power cables 77
which are connected to bus bars 78 and 80. Bus bar 78 is actually a
two-piece clamp bar which is effective to clamp the ends of a
plurality of heater strips 81.
These heater strips are formed of a suitable resistance heating
material, such as 0.012 inch chromel metal. The strips extend
transversely of the die assembly generally parallel to one another.
At the opposite side of the die assembly the strips are joined to
another bus bar 82. This second bus bar 82 is also secured to a
plurality of lower heating strips 83 which are similar to the first
set of strips and which pass beneath the lower portion of the
assembly 10 being fabricated and the lower die section. These lower
strips 83 are clamped to lower bus bar 80. It is to be understood
that bus bars 78, 80 and 82 are preferably carried by tension
springs 79 mounted on the sidewalls of housing member 16 in a
conventional manner. Suitable electrical insulation is
maintained.
It is to be understood that the power supply system for the
electrical heating elements is provided with conventional controls
for regulating the temperature developed by the resistance heating
elements. However, in some cases it develops that the temperature
is not uniform across the piece being brazed. Accordingly, one
aspect of the present invention contemplates the provision of means
for selectively lowering the temperature at one or more edge
portions of the braze assembly.
In brazing pieces of the type shown in FIG. 5, it has been
empirically determined that hot spots tend to develop adjacent to
the edges of the pieces. As shown in FIG. 5, these edges are
adapted to be selectively cooled by means of an electron emission
cooling circuit. It is to be understood that thermocouples (not
shown) are disposed at a plurality of points adjacent to the
working faces of the die members so that the temperature of every
area of the sandwich structure can be monitored continuously.
As shown in FIG. 5, a plurality of probes 84 are permanently
mounted within lower housing 16 and are electrically insulated
therefrom. The probes are spaced closely adjacent to one or the
other of the bus bars 78, 80 and 82. The probes are connected to a
high voltage source of direct current, for example, a source of the
order of 20-50 kv. The positive lines 85 of this source is
connected to the bus bar 78 while the negative leads 86 are
connected to the probes 84 as indicated diagrammatically in FIG. 5.
When it is desired to cool one or more of the localized areas
adjacent to one of the probes, the circuit is completed to that
probe from the high voltage AC supply. As a result, electrons are
emitted from the bus bar adjacent to the probe. This results in a
loss of energy in that portion of the bus bar and manifests itself
as a reduction in temperature. The temperature of the adjacent area
of the workpiece being brazed is lowered by conduction through the
adjacent heater strips to the cool spot on the bus bar.
A modified form of local cooling means is shown diagrammatically in
FIG. 10. As there shown, two tubes 110 and 111 extend parallel to
bus bars 78 and 82 respectively. These tubes are connected through
suitable valves to a source of water. When it is desired to cool
one side or the other of the honeycomb sandwich structure, water is
introduced into the tubes. The water flow maintains the temperature
of the tubes at a relatively low level so that heat radiates from
the adjacent bus bar to the tube. This reduces the temperature of
the adjacent edge of the sandwich structure by an amount sufficient
to reestablish a substantially uniform temperature across the
sandwich.
In addition to these elements, the present brazing apparatus
includes an upper, or hot, bladder 90 (see FIGS. 3, 4 and 6). This
bladder is disposed between the upper die member and the upper skin
12 of the workpiece. The bladder is fabricated from thin sheets of
stainless steel, or a similar heat resistant material, the
thickness of the bladder sheets preferably being from 0.015 inch to
0.025". The two sheets comprising the bladder are welded around the
entire periphery to form an airtight member. A connection is made
from the bladder to an inlet line which passes through the top wall
of housing section 15 and communicates with the interior of the
bladder. In the present embodiment, bladder 90 is preferably
fabricated so that its exterior dimensions correspond very closely
to the exterior dimensions of the panel.
Another component of the present brazing apparatus is shown in FIG.
8. As there shown, a vapor trap assembly 92 communicates with one
corner of housing member 15. The vapor trap assembly includes a
line 93 which opens through a suitable port in the housing and
communicates with a valve 94. The opposite side of valve 94 is
connected to an airtight chamber 95. Chamber 95 is a cold chamber
which includes a hollow internal well 96. This well Process open at
the top and is connected to the external wall of the chamber 95
through a narrow neck portion 97 which functions to minimize the
heat losses. The chamber is filled with an extremely cold material
such as liquid nitrogen. The temperature of this material is so low
that when valve 94 is opened and air circulates form the interior
of the housing to the cold chamber, any water vapor condenses out
of the atmosphere and freezes on the exterior surface of well 96.
This is shown diagrammatically by the frozen vapor patch 98 in FIG.
8.
PROCESS
In brazing parts utilizing the present method and apparatus, the
first step is the fabrication of the upper and lower die forms 32
and 33. The working faces of these die forms are shaped and the
longitudinal fluid passageways and ports are formed using
conventional techniques. Then upper die section 32 is mounted in
upper housing 15 and lower die section 33 is mounted in lower
housing section 16. Next, a pad of insulating cloth 100, such as a
three-quarter inch blanket of Kaowool material, is placed over the
working face of lower die member 33. Then, the lower resistance
heater strips 83 are secured to clamp bars 82 and 80 and are laid
over the Kaowool blanket. An insulating sheet 101 formed of fibrous
silica, or the like, is laid over the top of the heating strips 83.
A heat distributing sheet of copper, or the like, 102 is placed
over the top of the insulating sheet 101, and a slip sheet 99 of
stainless steel is laid over the copper sheet.
Next, the sandwich assembly 10 is placed over slip sheet 99. It is
to be understood that the core and two sandwich sheets 10 and 12
are temporarily adhered together by any suitable means, such as
tack brazing or tack welding. After the sandwich assembly 10 is in
place, a slip sheet 109 is placed over it and bag 90 is placed over
the slip sheet. It is to be understood that the bag is not
pressurized at this time. Thereafter, a copper sheet 103 is placed
on top of the bag and is covered by an insulating sheet of silica
fibers 104. Thereafter, the upper heating strips 81 are laid over
the top of the insulating sheet and are secured to clamp bars 82
and 78. The upper surfaces of the heating strips are covered by a
second insulating blanket 105 formed of Kaowool or the like.
Following this procedure, the upper housing member 15 is lowered
into contact with lower housing member 16. The clamps 26 are
tightened down to compress O-ring 24 and establish a peripheral
seal at a juncture of the upper and lower housing members.
In the next step, bags 90 and 48 are evacuated and the interior of
the housing is evacuated by means of a vacuum pump connected to
line 75. Following evacuation of the housing, the interior of the
housing is back-filled with argon through feed line 73. This
process of drawing a vacuum and back-filling can be repeated a
number of times if desired. The function of the argon back-filling
is to assist in flushing out the oxygen and water vapor in
particular and in replacing it on the surface of all materials
inside the braze tool. During this vacuum argon back-filling cycle,
power is applied to the heating elements 81 and 83 to bring the
temperature of the assembly to be brazed to approximately
500.degree. to thereby facilitate exchange of undesirable gas with
argon as a surface layer. Following the purging the interior of the
housing is filled with argon to its normal working pressure of 5"
of mercury. This pressure is accurately maintained by continuously
supplying a small quantity of argon through line 73 while
withdrawing a similar quantity of gas through vacuum line 75.
It is to be understood that during this time both upper bag 90 and
lower bag 48 are held under vacuum. Thus, there is only a nominal
force applied to the assembly being brazed and there is no
constriction to cause wrinkling, i.e. the material can seek its
proper position without wrinkling during the expansion phase.
After the interior of the housing has been placed under its
operating pressure, the of the part to be brazed is raised to
brazing temperature, normally a temperature of the order of
1950.degree. F. The total time required for the purging and
back-filling operation and to bring the part up to braze
temperature is o of the order of one hour. As the work reaches
brazing temperature, a pressure is applied to the interior of lower
bag 48. This bag raises lower die member 33 and causes the part
being brazed to generally accommodate itself to the working
surfaces of the lower and upper die.
Pressure is then applied to upper bag 90, This pressure of from 1/2
to 3 p.s.i. results in a brazing force being applied normal to the
surface of the part being brazed and of substantially equal
magnitude over the entire surface.
After the core has been held at brazing temperature a sufficient
length of time to effect a brazing operation, the upper and lower
bags are evacuated. This causes the lower die section 33 to be
lowered. At the same time, prechilled argon is fed to the manifolds
associated with the upper and lower die sections. This cold argon
flows through the longitudinal passageways formed in each die
member and escapes through the ports 43 and 71. The upper and lower
die sections are thus separated and the cooling gas is forced
through the many ports against the undersurface of copper sheet 101
and the upper surface of sheet 103. This causes brazed member 10 to
be lifted off the lower tool and, in effect, causes it to float
essentially between layers of coolant gas.
As a result of this action, the part is cooled rapidly, for
example, from a brazing temperature of 1950.degree. F. to a
temperature of 650.degree. F. in one hour. Thus, the total tool
operating time from the point at which upper and lower sections 15
and 16 are closed to the time that the part is cooled to handling
temperature is a total of 2 hours. The part is readily unloaded by
merely disconnecting the upper clamp bus bar 78.
It has been determined that parts brazed in accordance with this
method are superior to parts brazed by conventional techniques in
that they are less susceptible to wrinkling or distortion, and,
moreover, are possessed of a good, substantially uniform brazed
joint.
In a modification of the precess described above, a honeycomb core
sandwich structure can be shaped to a final simple or compound
curved configuration at the same time that the structure is brazed.
More particularly, in practicing this modified process, the core
and skin sheets constituting the panel assembly are tacked together
either in a planar configuration or in a lesser curvature than that
of the final configuration. This panel assembly is placed on the
lower die and is brazed in accordance with the process described
above. In this case, however, when the final pressure is applied to
the panel by upper bag member 90 after the panel has been raised to
brazing temperature, the panel is not only brazed but undergoes hot
creep forming which causes the panel to be shaped to its final
configuration.
From the above description of the general principles of the present
invention and the detailed disclosure of one preferred form of
method and one preferred form of apparatus, those skilled in the
art will readily comprehend various modifications to which the
present invention is susceptible. Therefore, I desire to be limited
only by the scope of the following claims.
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